JP2024519173A - Aerosol-forming compositions containing nicotine and an acid or a nicotine salt - Google Patents

Abstract

Aerosol generating materials having an aerosol generating composition, a consumable for use in a non-combustion aerosol delivery system, and a non-combustion aerosol delivery system. The consumable may include an aerosol generating composition. The aerosol generating composition may include an aerosol generating material. The aerosol generating material includes about 1 to about 30% by weight nicotine, about 15 to about 80% by weight gelling agent, about 10 to about 60% by weight aerosol-forming material, about 1 to about 30% by weight acid, and optionally a filler, wherein the molar ratio of nicotine to acid is 2.2:1 or less.
[Selected Figure] Figure 1

Description

Claiming priority

This application claims priority from U.S. Provisional Patent Application No. 63/193,877, filed May 27, 2021, which is incorporated by reference in its entirety herein.

The present invention relates to an aerosol generating composition including an aerosol generating material, a consumable for use in a non-combustion aerosol delivery system, the consumable including an aerosol generating composition, and a non-combustion aerosol delivery system.

background

Smoking articles, such as cigarettes and cigars, burn tobacco to produce tobacco smoke during use. Alternatives to these types of articles release inhalable aerosols or vapors by releasing compounds from a substrate material through heating without combustion. These are sometimes referred to as non-combustion smoking articles, aerosol generating assemblies, or non-combustion aerosol delivery systems.

One example of such a product is a heating device that releases compounds by heating but not burning a solid aerosolizable material, which in some examples may include tobacco material. The heating volatilizes at least one component of the material, typically forming an inhalable aerosol. These products are sometimes referred to as heat not burn devices, tobacco heating devices, or tobacco heating products (THPs). A variety of different configurations are known for volatilizing at least one component of a solid aerosolizable material.

Another example is an e-cigarette/tobacco heating product hybrid device, also known as an e-cigarette hybrid device. These hybrid devices include a liquid source (which may or may not contain nicotine) that is vaporized by heating to produce an inhalable vapor or aerosol. The device further includes a solid aerosolizable material (which may or may not contain tobacco material), the components of which are entrained in the inhalable vapor or aerosol to produce the inhalation medium.

Disclosure Summary

According to a first aspect of the present invention, there is provided an aerosol-forming composition comprising an aerosol-forming material, the aerosol-forming material comprising:
about 1% to about 30% by weight of nicotine;
about 15 to about 80 weight percent of a gelling agent;
about 10 to about 60 weight percent of an aerosol forming material;
about 1 to about 30 weight percent acid;
and optionally a filler, wherein weight percent values are calculated on a dry weight basis;
The molar ratio of nicotine to acid is less than or equal to 2.2:1.

According to a further aspect of the present invention there is provided an aerosol forming composition comprising an aerosol forming material, the aerosol forming material comprising:
about 5 to about 30% by weight of a nicotine salt;
about 15 to about 80 weight percent of a gelling agent;
about 10 to about 60 weight percent of an aerosol forming material;
and optionally a filler, where weight percentages are calculated on a dry weight basis.

According to a further aspect of the present invention there is provided an aerosol forming composition comprising an aerosol forming material, the aerosol forming material comprising:
about 1% to about 30% by weight of a nicotine salt;
about 45 to about 80 weight percent of a gelling agent;
about 10 to about 54 weight percent of an aerosol forming material;
and optionally a filler, where weight percentages are calculated on a dry weight basis.

According to a further aspect of the present invention, there is provided a consumable for use in a non-combustion aerosol delivery system, the consumable comprising an aerosol generating composition as defined herein.

According to a further aspect of the present invention, there is provided a non-combustion aerosol delivery system comprising a consumable as defined herein and a non-combustion aerosol delivery device comprising an aerosol generation device arranged to generate an aerosol from the consumable when the consumable is used with the non-combustion aerosol delivery device.

Further aspects of the invention described herein may provide for the use of an aerosol generating material, an aerosol generating composition, a consumable, or a non-combustion aerosol delivery system in generating an inhalable aerosol.

According to a further aspect of the present invention, there is provided a method of making the aerosol generating composition described herein.

Further features and advantages of the present invention will become apparent from the following description of preferred embodiments of the invention, which description is given by way of example only with reference to the accompanying drawings, in which:

FIG. 2 is a cross-sectional view of an example of a consumable item. FIG. 2 is a perspective view of the article of FIG. 1. FIG. 2 is a cross-sectional elevation view of an example consumable. FIG. 4 is a perspective view of the article of FIG. FIG. 1 is a perspective view of an example of a non-combustion aerosol delivery system. FIG. 1 is a cross-sectional view of an example of a non-combustion aerosol delivery system. FIG. 1 is a perspective view of an example of a non-combustion aerosol delivery system.

Detailed Description

The aerosol-generating compositions described herein are compositions capable of generating an aerosol when energized, for example, by heating, irradiation, or in any other manner. The aerosol-generating composition may be, for example, in the form of a solid, liquid, or gel, and includes nicotine. The aerosol-generating material may be an "amorphous solid." In some embodiments, the amorphous solid is a "monolithic solid." The aerosol-generating material may be non-fibrous or fibrous. In some embodiments, the aerosol-generating material may be a dry gel. The aerosol-generating material may be a solid material that may retain some fluid therein, e.g., liquid. In some embodiments, the retained fluid may be water (such as water absorbed from the surroundings of the aerosol-generating material) or the retained fluid may be a solvent (such as when the aerosol-generating material is formed from a slurry). In some embodiments, the solvent may be water. In some embodiments, the aerosol-generating composition may comprise, for example, about 50%, 60%, or 70% by weight of the aerosol-generating material to about 90%, 95%, or 100% by weight of the aerosol-generating material. These weight percent values are calculated on a wet weight basis (WWB), i.e., including water or other solvents present in the aerosol-generating composition or aerosol-generating material. In some examples, the aerosol-generating composition consists of the aerosol-generating material.

As described hereinabove, the present invention provides an aerosol-forming composition comprising (or consisting of) an aerosol-forming material, the aerosol-forming material comprising:
about 1% to about 30% by weight of nicotine;
about 15 to about 80 weight percent of a gelling agent;
about 10 to about 60 weight percent of an aerosol forming material;
about 1 to about 30 weight percent acid;
and optionally a filler, wherein weight percent values are calculated on a dry weight basis;
The molar ratio of nicotine to acid is less than or equal to 2.2:1.

Also provided is an aerosol-forming composition comprising (or consisting of) an aerosol-forming material, the aerosol-forming material comprising:
about 5 to about 30% by weight of a nicotine salt;
about 15 to about 80 weight percent of a gelling agent;
about 10 to about 60 weight percent of an aerosol forming material;
and optionally a filler, where weight percentages are calculated on a dry weight basis.

Also provided is an aerosol-forming composition comprising (or consisting of) an aerosol-forming material, the aerosol-forming material comprising:
about 1% to about 30% by weight of a nicotine salt;
45 to about 80% by weight of a gelling agent;
about 10 to about 54 weight percent of an aerosol forming material;
and optionally a filler, where weight percentages are calculated on a dry weight basis.

The presence of either an acid or a nicotine salt in the aerosol-generating material may improve the sensory properties of the aerosol by reducing harshness. If present, the acid protonates the nicotine to form a nicotine salt in situ, either in the material or in the aerosol as it is formed. The presence of a nicotine salt results in an aerosol that some users find more satisfying.

In some embodiments, the aerosol-generating material and/or the aerosol-generating composition consists essentially of or consists of a gelling agent, a solvent, an aerosol-forming material, nicotine, an acid, and optionally a flavoring and/or an optional further active and/or an optional filler.

In some embodiments, the aerosol-generating material and/or the aerosol-generating composition consists essentially of or consists of a gelling agent, a solvent, an aerosol-forming material, nicotine, an acid, and optionally a flavoring and/or an optional filler.

In some examples, the aerosol-generating material and/or the aerosol-generating composition consists essentially of or consists of a gelling agent, a solvent, an aerosol-forming material, nicotine, an acid, and a flavoring.

In some examples, the aerosol-generating material and/or the aerosol-generating composition consists essentially of or consists of a gelling agent, a solvent, an aerosol-forming material, nicotine, and an acid.

In some embodiments, the aerosol-generating material and/or the aerosol-generating composition consists essentially of or consists of a gelling agent, a solvent, an aerosol-forming material, a nicotine salt, and optionally a flavoring agent and/or an optional further active agent and/or an optional filler.

In some embodiments, the aerosol-generating material and/or the aerosol-generating composition consists essentially of or consists of a gelling agent, a solvent, an aerosol-forming material, a nicotine salt, and optionally a flavoring agent and/or an optional filler.

In some examples, the aerosol-generating material and/or the aerosol-generating composition consists essentially of or consists of a gelling agent, a solvent, an aerosol-forming material, a nicotine salt, and a flavoring agent.

In some examples, the aerosol-generating material and/or the aerosol-generating composition consists essentially of or consists of a gelling agent, a solvent, an aerosol-forming material, and a nicotine salt.

In each example, the solvent may be water. In some embodiments, the aerosol-generating material is a hydrogel and may contain less than about 20% water by weight, calculated on a wet weight basis. In some examples, the hydrogel may contain less than about 15%, 12%, or 10% water by weight, calculated on a wet weight basis (WWB). In some examples, the hydrogel may contain at least about 1%, 2%, or at least about 5% water by weight (WWB). Suitably, the water content of the aerosol-generating material may be from about 5%, 7%, or 9% to about 15%, 13%, or 11% by weight (WWB), e.g., 5-15%, 7-13%, or 9-11% by weight (WWB). The water content of the aerosol-generating material may be determined, for example, by Karl-Fischer titration or gas chromatography with a thermal conductivity detector (GC-TCD).

Aerosol-Forming Material The aerosol-forming material may include one or more components capable of forming an aerosol.

Suitably, the aerosol generating material may comprise from about 10% to about 60% by weight of the aerosol forming material (calculated on a dry weight basis), for example, from about 20%, 25%, or 30% to about 50%, or 55% by weight of the aerosol forming material. In an exemplary embodiment, the aerosol generating material comprises from about 15 to about 60% by weight of the aerosol forming material (calculated on a dry weight basis). In other exemplary embodiments, the aerosol generating material comprises from about 15 to 54%, from about 20 to 50%, from about 25 to 50%, or from about 30 to 50% by weight of the aerosol forming material.

In some embodiments, the aerosol forming material may include one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

In some embodiments, the aerosol forming material includes one or more polyhydric alcohols, such as glycerol, propylene glycol, triethylene glycol, 1,3-butanediol, and glycerin, esters of polyhydric alcohols, such as glycerol mono-, di-, or triacetate, and/or aliphatic esters of mono-, di-, or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

In some examples, the aerosol forming material comprises, consists essentially of, or consists of glycerol and/or propylene glycol.

In some embodiments, the aerosol forming material comprises a mixture of glycerol and propylene glycol in a weight ratio of about 3:1 to 1:3, about 2:1 to 1:2, about 1.5:1 to 1:1.5, about 55:45 to 45:55, or about 45:55 glycerol to propylene glycol.

In some examples, the aerosol forming material comprises, consists essentially of, or consists of glycerol.

Gelling Agent Suitably, the aerosol-forming material comprises from about 15% to about 80% by weight of gelling agent, for example from about 20%, 25%, 30%, 40%, or 45% to about 65%, 70%, or 75% by weight of gelling agent (all calculated on a dry weight basis). In exemplary embodiments, the aerosol-forming material comprises from about 20-80%, 35-80%, 45-80%, 40-70%, or 45-70% by weight of gelling agent.

In some embodiments, the gelling agent comprises a hydrocolloid.

In some embodiments, the gelling agent comprises (or is) one or more compounds selected from polysaccharide gelling agents, such as alginates, pectins, starches or derivatives thereof, cellulose or derivatives thereof, pullulan, carrageenan, agar and agarose, gelatin, gums, such as xanthan gum, guar gum and acacia gum, silica or silicone compounds, such as PDMS and sodium silicate, clays, such as kaolin, and polyvinyl alcohol.

In some embodiments, the gelling agent includes (or is) one or more polysaccharide gelling agents.

In some embodiments, the polysaccharide gelling agent is selected from alginate, pectin, starch or derivatives thereof, cellulose or derivatives thereof, and combinations thereof.

In some embodiments, the polysaccharide gelling agent is selected from alginates, cellulose derivatives, and combinations thereof.

In some embodiments, the gelling agent is a polysaccharide gelling agent, and optionally the polysaccharide gelling agent is selected from alginates, cellulose derivatives, and combinations thereof.

In some embodiments, the alginate is sodium alginate.

In some embodiments, the polysaccharide gelling agent is a cellulose derivative.

In some embodiments, the polysaccharide gelling agent is an alginate.

In some embodiments, the gelling agent is not cross-linked. The absence of cross-links in the gelling agent facilitates more rapid delivery of the cannabis component, derivative or extract (as well as any optional actives and/or flavorings) from the aerosol-forming material.

Examples of cellulose-based gelling agents (sometimes referred to herein as cellulose derivatives) include, but are not limited to, hydroxymethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose (CMC), hydroxypropylmethylcellulose (HPMC), methylcellulose, ethylcellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), and cellulose acetate propionate (CAP). In some embodiments, the cellulose or derivatives thereof are selected from hydroxymethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose (CMC), hydroxypropylmethylcellulose (HPMC), methylcellulose, ethylcellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), and cellulose acetate propionate (CAP). In some embodiments, the cellulose derivative is CMC.

For example, in some embodiments, the gelling agent includes (or is) one or more of alginate, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol.

In some embodiments, the gelling agent includes (or is) one or more of hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, guar gum, acacia gum, alginate, and/or pectin.

In some examples, the gelling agent may include (or be) an alginate and/or a pectin and may be combined with a cross-linking agent (such as a calcium source) during formation of the aerosol-forming material. In some examples, the aerosol-forming material may include a calcium-cross-linked alginate and/or a calcium-cross-linked pectin.

In some embodiments, the gelling agent comprises (or is) an alginate.

In some embodiments, alginate is the only gelling agent present in the aerosol-generating material.

In other embodiments, the gelling agent comprises an alginate and at least one additional gelling agent, such as pectin.

In certain embodiments, the gelling agent is carboxymethylcellulose.

In some embodiments, CMC is the only gelling agent present in the aerosol-generating material.

In some embodiments, the aerosol generating composition includes a cross-linking agent. In some examples, the cross-linking agent includes calcium ions. In some examples, the aerosol generating composition may include carboxymethylcellulose and calcium cross-linked alginate.

In some embodiments, the aerosol generating composition does not include a crosslinker.

Nicotine In some embodiments, the aerosol-forming material comprises from about 1% to about 30% nicotine by weight, for example, 3%, or 5% to about 10%, 15%, 20%, or 25% nicotine by weight (all calculated on a dry weight basis). In exemplary embodiments, the aerosol-forming material comprises 5-30%, 6-30%, 1-20%, 1-15%, 1-10%, or 2-10% nicotine by weight.

In some embodiments, the aerosol generating material comprises about 1% to about 30% by weight of acid, e.g., about 3%, or 5% to about 10%, 15%, 20%, or 25% by weight of acid (all calculated on a dry weight basis). In exemplary embodiments, the aerosol generating material comprises 5-30%, 6-30%, 1-20%, 1-15%, 1-10%, or 2-10% by weight of acid.

In some embodiments, the acid is an organic acid. In some embodiments, the acid may be at least one of a monobasic acid, a dibasic acid, and a tribasic acid. In some embodiments, the acid may include at least one carboxy functional group. In some such embodiments, the acid may be at least one of an alpha-hydroxy acid, a carboxylic acid, a dicarboxylic acid, a tricarboxylic acid, and a keto acid. In some such embodiments, the acid may be an alpha-keto acid.

In some such embodiments, the acid may be at least one of succinic acid, lactic acid, benzoic acid, citric acid, tartaric acid, fumaric acid, levulinic acid, acetic acid, malic acid, formic acid, sorbic acid, benzoic acid, propanoic acid, and pyruvic acid. In some embodiments, the acid is at least one of lactic acid, benzoic acid, levulinic acid, and pyruvic acid.

Preferably, the acid is benzoic acid. In other embodiments, the acid is lactic acid. In other embodiments, the acid may be an inorganic acid. In some of these embodiments, the acid may be a mineral acid. In some such embodiments, the acid may be at least one of sulfuric acid, hydrochloric acid, boric acid, and phosphoric acid.

Preferably, the aerosol-forming material comprises nicotine and an acid. In some embodiments, the molar ratio of nicotine to acid is 2.2:1 or less, 1.5:1 or less, or 1:1 or less.

In some embodiments, the molar ratio of nicotine to acid is 0.5:1 or more, 0.7:1 or more, or 0.8:1 or more. In some embodiments, the molar ratio is 0.5:1 to 2.2:1, 0.7:1 to 2:1, or 0.7:1 to 1.5:1.

In some embodiments, the molar ratio of acid to nicotine is 0.5:1 or more, 0.7:1 or more, or 0.8:1 or more. In some embodiments, the molar ratio of acid to nicotine is 0.5:1 to 2.2:1, 0.7:1 to 2:1, or 0.7:1 to 1.5:1.

In some embodiments, the aerosol generating material comprises about 1% to about 30% by weight of the nicotine salt, e.g., about 3%, or 5% to about 10%, 15%, 20%, or 25% by weight of the nicotine salt (all calculated on a dry weight basis). In exemplary embodiments, the aerosol generating material comprises 5-30%, 6-30%, 1-20%, 1-15%, 1-10%, or 2-10% by weight of the nicotine salt.

In some embodiments, the nicotine salt includes nicotine lactate or nicotine benzoate.

In some embodiments, the nicotine salt comprises, consists essentially of, or consists of nicotine benzoate.

Bulking Agents The aerosol-forming material may further comprise a bulking agent. The use of a bulking agent can help, for example, to reduce the stickiness of the aerosol-forming material when high levels of the aerosol-forming material are present.

In some embodiments, the aerosol generating material comprises less than about 10% by weight of filler, e.g., less than about 5% by weight of filler (all calculated on a dry weight basis). In some embodiments, the aerosol generating material comprises from about 1%, 2%, or 3% to about 5%, 7%, or 10% by weight, e.g., 1-10%, 2-7%, or 3-5% by weight.

In some examples, the aerosol generating material contains less than 1% by weight of filler.

In some examples, the aerosol generating material does not include a filler. In some examples, the aerosol generating composition does not include a filler.

When present, the filler may include one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents (such as molecular sieves). When present, the filler may include one or more organic filler materials, such as wood pulp, cellulose, and cellulose derivatives. In certain examples, the aerosol-generating material includes calcium carbonate, such as chalk.

In certain embodiments including a filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material, such as wood pulp, hemp fiber, cellulose, or a cellulose derivative. In some embodiments, the filler includes wood pulp. Without wishing to be bound by theory, it is believed that including a fibrous filler in the aerosol-generating material may increase the tensile strength of the material. This may be particularly advantageous in instances where the aerosol-generating material is provided as a sheet, for example, when a sheet of aerosol-generating material surrounds a rod of the aerosol-generating composition.

In some embodiments, the aerosol generating material may further include one or more other functional material(s).

Further Active Substances In certain embodiments, nicotine or a nicotine salt is the only active substance(s) present in the aerosol-generating material. In certain embodiments, nicotine or a nicotine salt is the only active substance(s) present in the aerosol-generating composition. However, the aerosol-generating material and/or the aerosol-generating composition may further comprise a further active ingredient.

In some examples, the aerosol-generating material may include, in addition to nicotine or a nicotine salt, from about 1%, 5%, 10%, 15%, 20%, or 25% to about 65%, 50%, 45%, 40%, 35%, or 30% by weight (calculated on a dry weight basis) of another active material.

The further active substance as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The further active substance may be selected from, for example, functional foods, nootropics, and psychoactive substances. The further active substance may be naturally occurring or synthetically obtained. The further active substance may include, for example, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, or components, derivatives, or combinations thereof. The further active substance may include one or more components, derivatives, or extracts of tobacco or another botanical substance.

In some embodiments, the additional active substances include caffeine, melatonin, or vitamin B12.

In some embodiments, the further active agent comprises cannabis component(s), derivative(s) or extract(s).

In some embodiments, the further active agent comprises one or more cannabinoid compounds selected from the group consisting of cannabidiol (CBD), tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiol acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabichromene (CBC), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), and cannabielsoin (CBE), cannabicitran (CBT).

The further active substance may comprise one or more cannabinoid compounds selected from the group consisting of cannabidiol (CBD) and THC (tetrahydrocannabinol).

Further active solids may include cannabidiol (CBD).

Active substances may include nicotine and cannabidiol (CBD).

Active substances may include nicotine, cannabidiol (CBD), and THC (tetrahydrocannabinol).

As described herein, the additional active may comprise or be derived from one or more botanical materials or components, derivatives or extracts thereof. As used herein, the term "botanical material" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husks, skins, and the like. Alternatively, the material may comprise active compounds naturally present in the botanical material or obtained synthetically. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, fragments, strips, sheets, and the like. Examples of botanical materials include tobacco, eucalyptus, star anise, hemp, cacao, coffee, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazel, hibiscus, bay leaf, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea (such as green or black tea), thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemongrass, lemon zest, lemon juice, lemon juice powder, lemon juice syrup ... Mont Peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiane, marjoram, olive, lemon balm, lemon basil, chive, Calvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof. The mint may be any of the following mint varieties: Mentha arventis, Grapefruit mint, Egyptian mint, Peppermint, Lime mint, Chocolate mint, Curly mint, Wild mint, Horse mint, Pineapple mint, Pennyroyal mint, and Common mint. pulegium), English spearmint (Mentha spicata c.v.), and apple mint (Mentha suaveolens).

In some embodiments, the further active agent comprises or is derived from one or more botanical substances or components, derivatives or extracts thereof, and the botanical substance is tobacco.

In some embodiments, the aerosol-generating material is substantially free of tobacco. "Substantially free" means that the material contains less than 1% by weight of tobacco, such as less than 0.5% by weight. In some embodiments, the aerosol-generating material does not contain tobacco. In some embodiments, the aerosol-generating material does not contain tobacco fiber. In certain embodiments, the aerosol-generating material does not contain fibrous material.

In some embodiments, the further active comprises or is derived from one or more botanical materials, or components, derivatives or extracts thereof, and the botanical materials are selected from eucalyptus, star anise, cocoa, and hemp. In some embodiments, the further active comprises (or is) a botanical material selected from eucalyptus, star anise, cocoa, and hemp.

In some embodiments, the further active comprises or is derived from one or more botanical materials, or components, derivatives or extracts thereof, and the botanical materials are selected from rooibos and fennel. In some embodiments, the further active comprises (or is) botanical material selected from rooibos and fennel.

Flavoring Agent The aerosol-forming material and/or the aerosol-forming composition may optionally include a flavoring agent. For example, the aerosol-forming material may include up to about 65%, 55%, 50%, or 45% by weight of flavoring agent. In some examples, the aerosol-forming material may include at least about 0.1%, 1%, 10%, 20%, 30%, 35%, or 40% by weight of flavoring agent (all calculated on a dry weight basis). For example, the aerosol-forming material may include 1-65%, 10-65%, 20-50%, or 30-40% by weight of flavoring agent.

As used herein, the terms "flavoring agent" and "flavoring agent" refer to materials that can be used to create a desired taste, aroma, or other somatic sensation in products intended for adult consumers, where local regulations permit. They may be naturally occurring flavoring materials, botanical materials, extracts of botanical materials, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese peppermint, aniseed (anise), cinnamon, turmeric, Indian spice, Asian spice, herb, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, paprika, or other flavorings). Pya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberries, mulberries, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, Caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, mint oil from any species of mint, eucalyptus, star anise, cacao, lemongrass, rooibos, flax, ginkgo, hazel, hibiscus, laurel, yerba mate, orange peel, rose, tea (green tea, black tea, etc.), thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, black currant, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chives, Calvi, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter receptor site blockers, sensory receptor site activators, or stimulants, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanical materials, or breath fresheners. They may be imitation, synthetic, or natural ingredients, or blends thereof. They may be in any suitable form, such as a liquid (such as an oil), a solid (such as a powder), or a gas.

In some embodiments, the flavoring includes menthol, spearmint, and/or peppermint.

In some embodiments, the flavoring includes cucumber, blueberry, citrus fruit, and/or red berry flavor components.

In some embodiments, the fragrance comprises eugenol.

In some embodiments, the flavoring comprises flavor components extracted from tobacco.

In some embodiments, the flavoring comprises flavor components extracted from cannabis.

In some embodiments, the flavoring may include sensory agents aimed at achieving somatic sensations that are typically chemically induced and perceived by stimulating the fifth cranial nerve (trigeminal nerve) in addition to or instead of the olfactory or gustatory nerves, and these may include agents that provide a heating effect, a cooling effect, a tingling effect, or a numbing effect. A suitable heating agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucolyptol or WS-3 (N-ethyl-2-isopropyl-5-methylcyclohexanecarboxamide).

In some examples, the aerosol forming material may further include an emulsifier, which emulsifies the molten flavoring during production. For example, the aerosol forming material may include about 5% to about 15% by weight of emulsifier (calculated on a dry weight basis), preferably about 10% by weight of emulsifier. The emulsifier may include gum acacia.

In some examples, the total content of additional actives and/or fragrances may be at least about 0.1%, 1%, 5%, 10%, 20%, 25%, or 30% by weight. In some examples, the total content of additional actives and/or fragrances may be less than about 60%, 50%, or 40% by weight (all calculated on a dry weight basis).

Colorants The aerosol-generating material may include a colorant. The addition of a colorant can change the visual appearance of the aerosol-generating material. The presence of a colorant in the aerosol-generating material can improve the visual appearance of the aerosol-generating material and the aerosol-generating composition. By adding a colorant to the aerosol-generating material, the aerosol-generating material can match the color of other components of the aerosol-generating composition or other components of the article that includes the aerosol-generating material.

Various colorants may be used depending on the desired color of the aerosol-generating material. The color of the aerosol-generating material may be, for example, white, green, red, purple, blue, brown, or black. Other colors are also contemplated. Natural or synthetic colorants may be used, such as natural or synthetic dyes, food grade colorants, and pharmaceutical grade colorants. In certain embodiments, the colorant is caramel, which may impart a brown appearance to the aerosol-generating material. In such embodiments, the color of the aerosol-generating material may be similar to the color of other components (e.g., tobacco materials) in the aerosol-generating composition that includes the aerosol-generating material. In some embodiments, the addition of a colorant to the aerosol-generating material renders the aerosol-generating material visually indistinguishable from other components in the aerosol-generating composition.

The colorant may be incorporated during the formation of the aerosol-generating material (e.g., when forming a slurry with the materials that form the aerosol-generating material), or the colorant may be applied to the aerosol-generating material after its formation (e.g., by spraying the colorant onto the aerosol-generating material).

Other Functional Ingredients The one or more other functional ingredients may include one or more of a pH adjuster, a preservative, a stabilizer, and/or an antioxidant.

In some embodiments, the aerosol-generating material is formed as a sheet. In some examples, the sheet of aerosol-generating material may be incorporated into a non-combustion aerosol delivery system or consumable in sheet form. The sheet of aerosol-generating material may be incorporated as a flat sheet, as a gathered or pleated sheet, as a corrugated sheet, as a rolled sheet (i.e., in the form of a tube), or as a strip (e.g., formed by cutting the sheet into elongated strips). In some such examples, the aerosol-generating material of these embodiments may be included in the system/consumable as a sheet, for example, as a sheet surrounding a rod of aerosolizable material (e.g., tobacco). For example, the sheet of aerosol-generating material may be formed on a wrapping paper that surrounds the aerosolizable material, such as tobacco. In other examples, the sheet may be shredded and then incorporated into an assembly, preferably mixed with aerosolizable material, such as cut rag tobacco.

In some examples, the aerosol-generating material may be in the form of a sheet or layer having a thickness of about 0.015 mm to about 1.0 mm. Suitably, the thickness may be in the range of about 0.05 mm, 0.1 mm, or 0.15 mm to about 0.5 mm, or 0.3 mm, for example 0.1 to 3 mm, or 0.15 to 0.3 mm. Materials having a thickness of 0.2 mm may be particularly suitable. The aerosol-generating material may comprise two or more layers, and the thicknesses described herein refer to the combined thicknesses of these layers.

If the aerosol-generating material is too thick, heating efficiency may be compromised, which will have a negative impact on power consumption during use. Conversely, if the aerosol-generating material is too thin, it may be difficult to manufacture and handle, and very thin materials may be more difficult to cast and more prone to breaking, which may impair aerosol formation during use.

The thicknesses specified herein are the average thickness of the material. In some examples, the thickness of the aerosol-generating material may vary by 25%, 20%, 15%, 10%, 5%, or 1% or less.

In some examples, the aerosol generating material in sheet form may have a tensile strength of about 200 N/m to about 2000 N/m. In some examples, the aerosol generating material in sheet form may have a tensile strength of about 200 N/m to about 900 N/m. In some examples, such as examples in which the aerosol generating material does not include a filler, the aerosol generating material in sheet form may have a tensile strength of about 200 N/m to about 400 N/m, or about 200 N/m to about 300 N/m, or about 250 N/m. Such tensile strengths may be particularly suitable for embodiments in which the aerosol generating material and/or aerosol generating composition are formed as a sheet and then shredded and incorporated into a consumable product. In some examples, such as those in which the aerosol-generating material includes a filler, the aerosol-generating material may have a tensile strength of about 600 N/m to about 900 N/m, or about 700 N/m to about 900 N/m, or about 800 N/m. Such tensile strengths may be particularly suitable for embodiments in which the aerosol-generating material and/or aerosol-generating composition is included in a consumable/non-combustion aerosol delivery system as a rolled sheet, preferably in the form of a tube.

The aerosol-generating composition including the aerosol-generating material may have any suitable areal density, for example, between 30 g/m ² and 120 g/m ^2. In some examples, the aerosol-generating material may have a mass per unit area of 80-120 g/m ² , or about 70-110 g/m ² , or particularly about 90-110 g/m ² , or preferably about 100 g/m ² (so that the sheet has a similar density to cut rag tobacco and mixtures of these materials do not easily separate). Such areal densities may be particularly suitable when the aerosol-generating composition is included in the assembly consumable/system in sheet form or as shredded sheets (as described further below). In some examples, the aerosol-generating composition may have a mass per unit area of about 30-70 g/m ² , 40-60 g/m ² , or 25-60 g/m ² and may be used to surround an aerosolizable material such as tobacco.

In some embodiments, the aerosol-generating material is formed as a film on a substrate. The aerosol-generating film may be a continuous film or a non-continuous film, such as a construction of separate pieces of film on a substrate. In some examples, the aerosol-generating film does not include a filler.

The aerosol-generating material used to generate the aerosol may be on or in a support to form a substrate. The support may be or include, for example, paper, card, paperboard, cardboard, recycled material, plastic material, ceramic material, composite material, glass, metal, or metal alloy. In some embodiments, the support comprises (or is) a susceptor. In some embodiments, the susceptor is an aluminum sheet. In some embodiments, the susceptor is embedded within the material. In some alternative embodiments, the susceptor is on one or both sides of the material.

The aerosol generating composition may include a carrier on which the aerosol generating material is disposed. The carrier acts as a support on which the layer of aerosol generating material is formed, facilitating manufacturing. The carrier may provide tensile strength to the layer of aerosol generating material, facilitating handling.

In some examples, the carrier may be formed from a material selected from metal foil, paper, carbon paper, greaseproof paper, ceramics, carbon allotropes (e.g., graphite and graphene), plastic, cardboard, wood, or combinations thereof. In some examples, the carrier may include or consist of tobacco material (such as a sheet of reconstituted tobacco). In some examples, the carrier may be formed from a material selected from metal foil, paper, cardboard, wood, or combinations thereof. In some examples, the carrier itself is a laminated structure comprising multiple layers of materials selected from the aforementioned list. In some examples, the carrier may also function as a flavor carrier. For example, the carrier may be impregnated with flavors or tobacco extracts.

In some examples, the carrier may be magnetic. This feature may be used to secure the carrier to a non-combustion aerosol delivery device during use, or to generate a particular aerosol generating material shape. In some examples, the aerosol generating composition may include one or more magnets that can be used to secure the material to an induction heater during use.

In some instances, the carrier may be substantially or completely impermeable to gases and/or aerosols. This prevents the aerosol or gas from passing through the carrier layer, thereby controlling the flow and ensuring that the aerosol or gas is delivered to the user. This may also be utilized to prevent the gas/aerosol from condensing or otherwise depositing during use, for example on the surface of a heater provided in the aerosol generation assembly. In this way, consumption efficiency and hygiene may be improved in some instances.

In some instances, the surface of the carrier that abuts the aerosol-generating material may be porous. For example, in one instance, the carrier comprises paper. A porous carrier such as paper has been found to be particularly suitable, with a porous (e.g., paper) layer abutting and forming a strong bond with a layer of aerosol-generating material. The aerosol-generating material may be formed by drying a gel, and, without being limited by theory, it is believed that the gel-forming slurry partially impregnates the porous carrier (e.g., paper) such that the carrier is partially bonded to the gel as it solidifies. This results in a strong bond between the gel and the carrier (and between the dried gel and the carrier).

In some embodiments, the aerosol-generating material may be laminated to a carrier, such as a paper sheet.

In some embodiments, when an aerosol-generating material is formed from a slurry as described herein, a layer of the slurry may be formed on a carrier, such as a paper sheet.

In addition, surface roughness can contribute to the strength of the bond between the aerosol-generating material and the carrier. The roughness of the paper (of the surface that contacts the carrier) is preferably in the range of 50-1000 Bekk seconds, preferably 50-150 Bekk seconds, preferably 100 Bekk seconds (measured over an air pressure range of 50.66-48.00 kPa). (The Bekk smoothness tester is an instrument used to measure the smoothness of paper surfaces. In this tester, air at a specific pressure is inserted between a smooth glass surface and a paper sample. The time (in seconds) for a fixed volume of air to penetrate between these surfaces is the "Bekk smoothness").

Conversely, the surface of the carrier that does not face the aerosol-generating material may be placed in contact with the heater, and the smoother surface may provide more efficient heat transfer. Thus, in some examples, the carrier is positioned to have a rougher surface that abuts the aerosol-generating material and a smoother surface that does not face the aerosol-generating material.

In one particular example, the carrier may be a paper-backed foil, where the paper layer abuts against the layer of aerosol-generating material, providing the properties discussed in the previous paragraphs. The foil backing is substantially impermeable and provides control of the aerosol flow path. The metal foil backing may also act to transfer heat to the aerosol-generating material.

In another example, a foil layer of a paper-backed foil abuts the aerosol-generating material. The foil is substantially impermeable, thereby preventing moisture provided in the aerosol-generating material from being absorbed by the paper, which could weaken the structural integrity of the paper.

In some examples, the carrier is formed from or includes a metal foil (such as aluminum foil). A metallic carrier may allow for better transfer of thermal energy to the aerosol generating material. Additionally or alternatively, the metal foil may function as a susceptor in an induction heating system. In certain embodiments, the carrier comprises a metal foil layer and a support layer (such as cardboard). In these embodiments, the metal foil layer may have a thickness of less than 20 μm, for example, from about 1 μm to about 10 μm, preferably about 5 μm.

In some examples, the carrier may have a thickness of about 0.010 mm to about 2.0 mm, preferably about 0.015 mm, 0.02 mm, 0.05 mm, or 0.1 mm to about 1.5 mm, 1.0 mm, or 0.5 mm.

In another aspect of the present disclosure, a consumable for use in a non-combustion type aerosol delivery device is provided, the consumable comprising an aerosol generating composition, the aerosol generating composition comprising (or consisting of) an aerosol generating material, the aerosol generating material comprising:
about 1% to about 30% by weight of nicotine;
about 15 to about 80 weight percent of a gelling agent;
about 10 to about 60 weight percent of an aerosol forming material;
about 1 to about 30 weight percent acid;
and optionally a filler, wherein weight percent values are calculated on a dry weight basis;
The molar ratio of nicotine to acid is less than or equal to 2.2:1.

In another aspect of the present disclosure, a consumable for use in a non-combustion type aerosol delivery device is provided, the consumable comprising an aerosol generating composition, the aerosol generating composition comprising (or consisting of) an aerosol generating material, the aerosol generating material comprising:
about 5 to about 30% by weight of a nicotine salt;
about 15 to about 80 weight percent of a gelling agent;
about 10 to about 60 weight percent of an aerosol forming material;
and optionally a filler, where weight percentages are calculated on a dry weight basis.

In another aspect of the present disclosure, a consumable for use in a non-combustion type aerosol delivery device is provided, the consumable comprising an aerosol generating composition, the aerosol generating composition comprising (or consisting of) an aerosol generating material, the aerosol generating material comprising:
about 1% to about 30% by weight of a nicotine salt;
about 45 to about 80 weight percent of a gelling agent;
about 10 to about 54 weight percent of an aerosol forming material;
and optionally a filler, where weight percentages are calculated on a dry weight basis.

In some embodiments, the present disclosure relates to consumables that include an aerosol generating composition and are configured for use with a non-combustion aerosol delivery device. These consumables may be referred to as articles throughout this disclosure.

The consumables may be used with any suitable non-combustion aerosol delivery device.

A consumable item is an article that contains or consists of an aerosol-forming composition that is intended to be consumed in part or in whole during use by a user.

The consumable may include one or more other components, such as an aerosol-generating composition storage area, an aerosol-generating composition transfer component, an aerosol-generating area, a housing, a wrapper, a mouthpiece, a filter, and/or an aerosol modifier. The consumable may also include an aerosol generator, such as a heater that generates heat upon use to cause generation of an aerosol from the aerosol-generating composition. The heater may include, for example, a combustible material, a material heatable by electrical conduction, or a susceptor.

In some embodiments, the consumable contains a single aerosol generating composition. That is, the consumable contains an aerosol generating composition as defined herein and does not contain other aerosol generating component(s), active material(s), agent(s), or composition(s).

In some embodiments, the consumable is substantially free of tobacco. "Substantially free" means that the material contains less than 1% by weight of tobacco, for example less than 0.5% by weight. In some embodiments, the consumable does not contain tobacco. In some embodiments, the consumable does not contain tobacco fiber.

A susceptor is a material that can be heated by passing it through a varying magnetic field, e.g., an alternating magnetic field. The susceptor may be an electrically conductive material, in which case passing it through a varying magnetic field causes inductive heating of the heating material. The heating material may be a magnetic material, in which case passing it through a varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both electrically conductive and magnetic, in which case the susceptor is heatable by both heating mechanisms. A device configured to generate a varying magnetic field is referred to herein as a magnetic field generator.

An aerosol modifier is a substance, typically located downstream of the aerosol-generation region, configured to modify the aerosol generated, for example, by altering the taste, flavor, acidity, or another property of the aerosol. The aerosol modifier may be included in an aerosol modifier-releasing component that is operable to selectively release the aerosol modifier.

The aerosol modifier may be, for example, an additive or an adsorbent. The aerosol modifier may include, for example, one or more of a flavoring, a colorant, water, and a carbon adsorbent. The aerosol modifier may be, for example, a solid, liquid, or gel. The aerosol modifier may be in powder, thread, or granular form. The aerosol modifier may not include a filtration material.

The aerosol generator is a device configured to cause the generation of an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to thermal energy to release one or more volatile substances from the aerosol-generating composition to form an aerosol. In some embodiments, the aerosol generator is configured to cause the generation of an aerosol from the aerosol-generating composition without the application of heat. For example, the aerosol generator may be configured to subject the aerosol-generating composition to one or more of vibrational, high pressure, or electrostatic energy.

Non-combustion aerosol delivery system In another aspect of the present disclosure, a non-combustion aerosol delivery system is provided that includes a consumable and a non-combustion aerosol delivery device as described herein.

According to this disclosure, a "non-combustion" aerosol delivery system is one in which the component aerosol-generating materials (or components thereof) of the aerosol delivery system are not combusted or burned to facilitate delivery of at least one substance to a user.

In some embodiments, the delivery system is a non-combustion aerosol delivery system, for example a powdered non-combustion aerosol delivery system.

In some embodiments, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system. An example of such a system is a tobacco heating system.

In some embodiments, the non-combustion aerosol delivery device is a non-combustion heated device.

In some embodiments, the non-combustion aerosol delivery system is a hybrid system that generates an aerosol using a combination of aerosol-generating materials, one or more of which may be heated. In some embodiments, the hybrid system includes an aerosol-generating material as described herein that includes or consists of an aerosol-generating material and an additional liquid or gel aerosol-generating material.

In some embodiments, the non-combustion aerosol delivery device is an e-cigarette hybrid device.

Typically, a non-combustion aerosol delivery system may include a non-combustion aerosol delivery device and a consumable for use with the non-combustion aerosol delivery device.

In some embodiments, the non-combustion aerosol delivery system, e.g., the non-combustion aerosol delivery device, may include a power source and a controller. The power source may be, for example, an electrical power source or a heat generating power source. In some embodiments, the heat generating power source includes a carbon substrate that may be energized to distribute electrical power in the form of heat to the aerosol generating material or a heat transfer material proximate to the heat generating power source.

In some embodiments, the non-combustion aerosol delivery system, e.g., the non-combustion aerosol delivery device, may include a consumable receiving area, an aerosol generator, an aerosol generating area, a housing, a mouthpiece, a filter, and/or an aerosol modifier.

A non-combustion aerosol delivery system or device may include a heater configured to heat but not combust the aerosol-generating substrate. The heater may, in some examples, be a thin-film electrical resistance heater. In other examples, the heater may comprise an induction heater or other heater. In still further examples, the heater may be a combustible heat source or a chemical heat source that undergoes an exothermic reaction to generate heat during use.

In some examples, the heater, in use, may heat the aerosolizable material(s) to between 120°C and 350°C without burning the aerosolizable material(s). In some examples, the heater, in use, may heat the aerosolizable material(s) to between 140°C and 250°C without burning the aerosolizable material(s). In some examples, in use, substantially the entirety of the aerosol-generating material is less than about 4 mm, 3 mm, 2 mm, or 1 mm from the heater. In some examples, the solid is disposed between about 0.017 mm and 2.0 mm, preferably between about 0.1 mm and 1.0 mm, from the heater. These minimum distances may, in some examples, reflect the thickness of a carrier supporting the aerosol-generating material. In some examples, a surface of the aerosol-generating material may directly abut the heater.

In some examples, the heater may be embedded in the aerosol generating material. In some such examples, the heater may be an electrical resistance heater (with exposed contacts for connection to an electrical circuit). In other such examples, the heater may be a susceptor embedded in the aerosol generating material that is heated by induction.

The non-combustion aerosol delivery system may further comprise a cooling element and/or a filter. If a cooling element is present, the cooling element may act or function to cool the gaseous or aerosol components. In some instances, the cooling element may act to cool the gaseous components such that they condense to form an aerosol. The cooling element may also act to move a very hot portion of the device away from the user. If a filter is present, the filter may comprise any suitable filter known in the art, such as a cellulose acetate plug.

In some examples, the non-combustion aerosol delivery system may be a non-combustion heated system. That is, the non-combustion aerosol delivery system may include a solid material (and not a liquid aerosolizable material). A non-combustion heated device is disclosed in WO 2015/062983 A2, the entirety of which is incorporated herein by reference.

In some examples, the non-combustion aerosol delivery system may be an e-cigarette hybrid device. That is, the non-combustion aerosol delivery system may include a solid aerosolizable material and a liquid aerosolizable material. These separate aerosolizable materials may be heated by separate heaters or may be heated by the same heater, or in some examples, the downstream aerosolizable material may be heated by a hot aerosol generated from the upstream aerosolizable material. An e-cigarette hybrid device is disclosed in WO 2016/135331 A1, the entirety of which is incorporated herein by reference.

Alternatively, the consumable may be referred to herein as a cartridge. The consumable may be adapted for use in a THP, an e-cigarette hybrid device, or another aerosol generating device. In some examples, the consumable may further comprise a filter and/or a cooling element as previously described. In some examples, the consumable may be surrounded by a packaging material, such as paper.

The consumable may further comprise vent holes. These may be provided in the sidewalls of the article. In some instances, the vent holes may be provided in the filter and/or cooling element. These holes allow cool air to be drawn into the article during use, where it can mix with the heated volatile components, thereby cooling the aerosol.

Ventilation facilitates the production of visible heated volatiles from the article when the article is heated in use. The heated volatiles are made visible by a process of cooling the heated volatiles such that supersaturation of the heated volatiles occurs. The heated volatiles then undergo droplet formation (also known as nucleation) and ultimately the size of the aerosol particles of the heated volatiles increases due to further condensation of the heated volatiles and by coalescence of the newly formed droplets from the heated volatiles.

In some instances, the ratio of cool air to the sum of heated volatiles and cool air (known as the ventilation ratio) is at least 15%. A ventilation ratio of 15% allows the heated volatiles to be visualized by the methods described above. The visibility of the heated volatiles allows the user to discern that volatiles are being produced, enhancing the sensory experience of the smoking experience.

In another example, the ventilation ratio is between 50% and 85% to further cool the heated volatile components. In some examples, the ventilation ratio may be at least 60% or 65%.

With reference to Figures 1 and 2, a partial cutaway cross-sectional view and a perspective view of an example of an article consumable 101 (Article) are shown. The Article 101 is adapted for use with a device having a power source and a heater. This embodiment of the Article 101 is particularly suited for use with the Device 1 shown in Figures 5-7 described below. In use, the Article 101 can be removably inserted into the device at an insertion point 20 of the Device 1 shown in Figure 5.

The example article 101 is in the form of a generally cylindrical rod including an aerosol generating composition body 103 and a filter assembly 105 in the form of a rod. The aerosol generating material includes an aerosol generating material as described herein. In some embodiments, it may be included in sheet form. In some embodiments, it may be included in chopped sheet form. In some embodiments, the aerosol generating material as described herein may be incorporated in both sheet form and chopped form.

The filter assembly 105 includes three segments: a cooling segment 107, a filter segment 109, and an oral end segment 111. The article 101 has a first end 113, also known as the oral end or proximal end, and a second end 115, also known as the distal end. The aerosol generating composition body 103 is disposed at the distal end 115 of the article 101. In one example, the cooling segment 107 is disposed adjacent to the aerosol generating composition body 103 between the aerosol generating composition body 103 and the filter segment 109 such that the cooling segment 107 is in abutting relationship with the aerosol generating composition 103 and the filter segment 109. In another example, there may be a separation between the aerosol generating composition body 103 and the cooling segment 107 and between the aerosol generating composition body 103 and the filter segment 109. The filter segment 109 is disposed between the cooling segment 107 and the oral end segment 111. The oral end segment 111 is disposed toward the proximal end 113 of the article 101 and is adjacent to the filter segment 109. In one example, the filter segment 109 is in an abutting relationship with the oral end segment 111. In one embodiment, the overall length of the filter assembly 105 is between 37 mm and 45 mm, and more preferably, the overall length of the filter assembly 105 is 41 mm.

In one example, the rod of aerosol generating composition 103 has a length between 34 mm and 50 mm, preferably between 38 mm and 46 mm, and preferably has a length of 42 mm.

In one example, the overall length of the item 101 is between 71 mm and 95 mm, preferably between 79 mm and 87 mm, and preferably 83 mm.

One axial end of the aerosol generating composition body 103 is visible at the distal end 115 of the article 101. However, in other embodiments, the distal end 115 of the article 101 may include an end member (not shown) that covers one axial end of the aerosol generating composition body 103.

The aerosol generating composition body 103 is joined to the filter assembly 105 by an annular tipping paper (not shown) that is disposed substantially around the filter assembly 105 so as to surround the filter assembly 105 and extends partially along the length of the aerosol generating composition body 103. In one example, the tipping paper is made from 58 GSM standard tipping base paper. In one example, the tipping paper has a length of 42 mm to 50 mm, preferably 46 mm.

In one example, the cooling segment 107 is an annular tube that is disposed around and defines a cavity within the cooling segment. The cavity provides a chamber through which heated volatile components generated from the aerosol generating composition body 103 flow. The cooling segment 107 is hollow to provide a chamber for aerosol accumulation, yet is rigid enough to withstand axial compressive forces and bending moments that may occur during manufacture and use of the article 101 during insertion into the device 1. In one example, the wall thickness of the cooling segment 107 is about 0.29 mm.

The cooling segment 107 provides a physical displacement between the aerosol generating composition 103 and the filter segment 109. The physical displacement provided by the cooling segment 107 provides a thermal gradient across the length of the cooling segment 107. In one example, the cooling segment 107 is configured to provide a temperature difference of at least 40 degrees Celsius between the heated volatile component entering the first end of the cooling segment 107 and the heated volatile component exiting the second end of the cooling segment 107. In one example, the cooling segment 107 is configured to provide a temperature difference of at least 60 degrees Celsius between the heated volatile component entering the first end of the cooling segment 107 and the heated volatile component exiting the second end of the cooling segment 107. This temperature difference across the length of the cooling element 107 protects the temperature-sensitive filter segment 109 from the high temperatures of the aerosol generating composition 103 when the aerosol generating composition 103 is heated by the device 1. If no physical displacement is provided between the filter segment 109 and the aerosol generating composition body 103 and the heating element of the device 1, the temperature sensitive filter segment 109 may become damaged during use and may no longer effectively perform its required function.

In one example, the length of the cooling segment 107 is at least 15 mm. In one example, the length of the cooling segment 107 is between 20 mm and 30 mm, more specifically between 23 mm and 27 mm, more specifically between 25 mm and 27 mm, preferably 25 mm.

The cooling segment 107 is made of paper, meaning that it is constructed from a material that does not generate compounds of concern (e.g., toxic compounds) when adjacent to the heater of the device 1 in use. In one example, the cooling segment 107 is manufactured from a spirally wound paper tube that provides a hollow interior chamber but maintains mechanical rigidity. The spirally wound paper tube can meet the stringent dimensional accuracy requirements of high speed manufacturing processes for tube length, outer diameter, roundness, and straightness.

In another example, the cooling segment 107 is a recess made from stiff plug wrap or tipping paper. The stiff plug wrap or tipping paper is manufactured to be sufficiently stiff to withstand axial compressive forces and bending moments that may occur during manufacture and use of the article 101 during insertion into the device 1.

The filter segment 109 may be formed from any filter material sufficient to remove one or more volatile compounds from the heated volatile components from the aerosol generating material. In one example, the filter segment 109 is made from a monoacetate material, such as cellulose acetate. The filter segment 109 provides cooling and reduced irritation of the heated volatile components without depleting the amount of the heated volatile components to an unsatisfactory level for the user.

In some embodiments, a capsule (not shown) may be provided within the filter segment 109. The capsule may be substantially centered within the filter segment 109, both radially and longitudinally. In other examples, the capsule may be off-center in one or more dimensions. In some examples, the capsule, if present, may contain a volatile component, such as a flavoring or an aerosol-forming material.

The density of the cellulose acetate tow material of the filter segment 109 controls the pressure drop across the filter segment 109, which in turn controls the resistance to suction of the article 101. Therefore, the selection of the material for the filter segment 109 is important in controlling the resistance to suction of the article 101. Furthermore, the filter segment performs a filtration function in the article 101.

In one example, the filter segment 109 is made of 8Y15 grade filter tow material, which provides a filtering effect on the heated volatilized material while reducing the size of the condensed aerosol droplets resulting from the heated volatilized material.

The presence of the filter segment 109 provides an insulating effect by further cooling the heated volatile components exiting the cooling segment 107. This additional cooling effect reduces the contact temperature of the user's lips against the surface of the filter segment 109.

In one example, the filter segment 109 has a length of 6 mm to 10 mm, preferably 8 mm.

The mouth end segment 111 is an annular tube that is disposed around and defines a cavity within the mouth end segment 111. The cavity provides a chamber for heated volatile components flowing from the filter segment 109. The mouth end segment 111 is hollow to provide a chamber for aerosol accumulation, but is rigid enough to withstand axial compressive forces and bending moments that may occur during use of the article during manufacture and insertion into the device 1. In one example, the wall thickness of the mouth end segment 111 is about 0.29 mm. In one example, the length of the mouth end segment 111 is between 6 mm and 10 mm, preferably 8 mm.

The mouth end segment 111 may be manufactured from a spiral wound paper tube that provides a hollow interior chamber but maintains significant mechanical rigidity. A spiral wound paper tube can meet the stringent dimensional accuracy requirements of high speed manufacturing processes for tube length, outer diameter, roundness and straightness.

The mouth end segment 111 serves the function of preventing liquid condensate that accumulates at the outlet of the filter segment 109 from coming into direct contact with the user.

It should be appreciated that in one example, the oral end segment 111 and the cooling segment 107 may be formed from a single tube, with the filter segment 109 disposed within the tube to separate the oral end segment 111 and the cooling segment 107.

Referring to Figures 3 and 4, a partial cutaway cross-sectional view and a perspective view of an example of an article 301 are shown. The reference numbers shown in Figures 3 and 4 correspond to the reference numbers shown in Figures 1 and 2, but are increased by 200.

In the example of article 301 shown in Figures 3 and 4, a ventilation area 317 is provided in article 301 to allow air to flow from the exterior of article 301 to the interior of article 301. In one example, ventilation area 317 takes the form of one or more ventilation holes 317 formed through an outer layer of article 301. The ventilation holes may be located in cooling segment 307 to aid in cooling article 301. In one example, ventilation area 317 comprises one or more rows of holes, preferably each row of holes located along the periphery of article 301 in a cross section substantially perpendicular to the longitudinal axis of article 301.

In one example, there are 1-4 rows of vent holes to provide ventilation to the article 301. Each row of vent holes may have 12-36 vent holes 317. The diameter of the vent holes 317 may be, for example, 100-500 μm. In one example, the axial spacing between the rows of vent holes 317 is 0.25 mm-0.75 mm, preferably 0.5 mm.

In one example, the vent holes 317 have a uniform size. In another example, the vent holes 317 have a variety of sizes. The vent holes can be created using any suitable technique, such as one or more of laser techniques, mechanical drilling of the cooling segment 307, or pre-drilling of the cooling segment 307 before it is formed in the article 301. The vent holes 317 are positioned to effectively cool the article 301.

In one example, the row of ventilation holes 317 is located at least 11 mm from the proximal end 313 of the article, and preferably 17 mm to 20 mm from the proximal end 313 of the article 301. The ventilation holes 317 are located such that the user does not block the ventilation holes 317 when the article 301 is in use.

By providing a row of vent holes 17-20 mm from the proximal end 313 of the article 301, the vent holes 317 can be located on the outside of the device 1 when the article 301 is fully inserted into the device 1, as seen in Figures 6 and 7. By locating the vent holes on the outside of the device, unheated air can enter the article 301 from outside the device 1 through the vent holes to help cool the article 301.

The length of the cooling segment 307 is such that when the item 301 is fully inserted into the device 1, the cooling segment 307 is partially inserted into the device 1. This length of the cooling segment 307 provides a first function of providing a physical gap between the heating device of the device 1 and the heat-sensitive filter device 309, and a second function of allowing the vent hole 317 to be located within the cooling segment while also being located outside the device 1 when the item 301 is fully inserted into the device 1. As can be seen from Figures 6 and 7, most of the cooling element 307 is located within the device 1. However, there is a portion of the cooling element 307 that extends outside the device 1. The vent hole 317 is located in this portion of the cooling element 307 that extends outside the device 1.

Referring now in more detail to Figures 5-7, an example of a device 1 is shown that is configured to heat an aerosol generating composition to volatilize at least one component of said aerosol generating material, typically to form an inhalable aerosol. Device 1 is a heating device that releases compounds by heating but not combusting the aerosol generating material.

The first end 3 may be referred to herein as the oral or proximal end 3 of the device 1, and the second end 5 may be referred to herein as the distal end 5 of the device 1. The device 1 has an on/off button 7, allowing the entire device 1 to be activated/deactivated as desired by the user.

The device 1 includes a housing 9 for arranging and protecting the various internal components of the device 1. In the illustrated example, the housing 9 includes a unitary sleeve 11 that surrounds the outer edge of the device 1 and is capped with a top panel 17 that generally forms the "top" of the device 1 and a bottom panel 19 that generally forms the "bottom" of the device 1. In another example, the housing includes a front panel, a rear panel, and a pair of opposing side panels in addition to the top panel 17 and bottom panel 19.

The top panel 17 and/or bottom panel 19 may be removably secured to the unitary sleeve 11 to allow easy access to the interior of the device 1, or may be "permanently" secured to the unitary sleeve 11, for example to prevent a user from accessing the interior of the device 1. In one example, the panels 17 and 19 are made of a plastic material (including glass-filled nylon formed by injection molding, etc.) and the unitary sleeve 11 is made of aluminum, although other materials and other manufacturing processes may be used.

The top panel 17 of the device 1 has an opening 20 at the mouth end 3 of the device 1 through which a user can insert and remove an article 101, 301 containing an aerosol-generating material into and from the device 1 during use.

The housing 9 has disposed therein or secured thereto the heating device 23, the control circuitry 25, and the power source 27. In this example, the heating device 23, the control circuitry 25, and the power source 27 are laterally adjacent (i.e., adjacent when viewed from one end), and the control circuitry 25 is generally located between the heating device 23 and the power source 27, although other arrangements are possible.

The control circuitry 25 may include a controller, such as a microprocessor device, configured and arranged to control the heating of the aerosol generating material within the article 101, 301, as discussed further below.

The power source 27 may be, for example, a battery, which may be a rechargeable or non-rechargeable battery. Examples of suitable batteries include, for example, lithium ion batteries, nickel batteries (e.g., nickel cadmium batteries), alkaline batteries, and the like. The battery 27 is electrically coupled to the heating device 23 and provides power under the control of the control circuitry 25 when needed to heat the aerosol-forming material within the article (to volatilize the aerosol-forming material without burning it, as described above).

The advantage of placing the power source 27 laterally adjacent to the heating apparatus 23 is that a physically larger power source 25 can be used without making the overall device 1 excessively long. Of course, a physically larger power source 25 will generally have a higher capacity (i.e., total electrical energy it can provide, often measured in ampere-hours or the like) and therefore may provide a longer battery life for the device 1.

In one example, the heating device 23 is generally in the form of a hollow cylindrical tube having a hollow internal heating chamber into which the article 101, 301 comprising the aerosol generating composition is inserted for heating during use. Various configurations of the heating device 23 are possible. For example, the heating device 23 may comprise a single heating element or may be formed from multiple heating elements aligned along the longitudinal axis of the heating device 23. The or each heating element may be annular or tubular, or may be at least partially annular or at least partially tubular along its circumference. In one example, the or each heating element may be a thin film heater. In another example, the or each heating element may be made from a ceramic material. Examples of suitable ceramic materials include alumina and aluminum nitride ceramics, as well as silicon nitride ceramics, which may be layered and sintered. Other heating configurations are possible, including, for example, induction heating, infrared heating elements (which heat by radiating infrared radiation), resistive heating elements formed by resistive electrical windings, and the like.

In one particular example, the heating device 23 is supported by a stainless steel support tube and includes a polyimide heating element. The heating device 23 is dimensioned such that when the article 101, 301 is inserted into the device 1, substantially the entire body of the article 101, 301, which comprises the aerosol generating composition 103, 303, is inserted into the heating device 23.

The or each heating element may be arranged to heat selected zones (areas) of the aerosol-generating material independently, for example sequentially (over time as described above) or together (simultaneously), as desired.

The heating device 23 in this example is surrounded by insulation 31 along at least a portion of its length. The insulation 31 helps to reduce heat passing from the heating device 23 to the exterior of the device 1. This generally reduces heat loss and therefore helps to keep the power requirements of the heating device 23 low. The insulation 31 also helps to keep the exterior of the device 1 cool during operation of the heating device 23. In one example, the insulation 31 may be a double-walled sleeve that provides a low pressure area between the two walls of the sleeve. That is, the insulation 31 may be, for example, a "vacuum" tube, i.e., a tube that is at least partially evacuated to minimize heat transfer by conduction and/or convection. Other configurations for the insulation 31 are possible, including the use of an insulating material (including, for example, a suitable foam-type material) in addition to or instead of the double-walled sleeve.

The housing 9 may further include various internal support structures 37 for supporting all internal components as well as the heating device 23.

The device 1 further comprises a collar 33 extending around the opening 20 and projecting from the opening 20 into the interior of the housing 9, and a generally tubular chamber 35 disposed between the collar 33 and one end of the vacuum sleeve 31. The chamber 35 further comprises a cooling structure 35f, which in this example comprises a plurality of cooling fins 35f spaced along the outer surface of the chamber 35, each fin being disposed to surround the outer surface of the chamber 35. When the article 101, 301 is inserted into the device 1 over at least a portion of the length of the hollow chamber 35, there is a gap 36 between the hollow chamber 35 and the article 101, 301. The gap 36 surrounds the entire circumference of the article 101, 301 over at least a portion of the cooling segment 307.

The collar 33 includes a number of ridges 60 arranged around the periphery of the opening 20, which protrude into the opening 20. The ridges 60 occupy space within the opening 20 such that the opening distance of the opening 20 at the location of the ridges 60 is less than the opening distance of the opening 20 without the ridges 60. The ridges 60 are configured to engage with an article 101, 301 inserted into the device to help secure it within the device 1. The open spaces (not shown) defined by adjacent pairs of the ridges 60 and the articles 101, 301 form ventilation paths around the outer surfaces of the articles 101, 301. These ventilation paths allow hot steam escaping from the articles 101, 301 to exit the device 1, and allow cooling air to flow into the device 1 around the articles 101, 301 within the gap 36.

In operation, the article 101, 301 is removably inserted into the insertion site 20 of the device 1, as shown in Figures 5-7. With particular reference to Figure 6, in one example, the aerosol generating composition body 103, 303 (which is disposed at the distal end 115, 315 of the article 101, 301) is completely contained within the heating arrangement 23 of the device 1. The proximal end 113, 313 of the article 101, 301 extends from the device 1 and functions as a mouthpiece assembly for the user.

During operation, the heating device 23 heats the article 101, 301 to volatilize at least one component of the aerosol-generating composition from the aerosol-generating material body 103, 303.

The primary flow path for the heated volatile components from the aerosol-generating composition body 103, 303 is axially through the article 101, 301, through the inner chamber of the cooling segment 107, 307, through the filter segment 109, 309, and through the mouth end segment 111, 311 to the user. In one example, the temperature of the heated volatile components generated from the aerosol-generating material body is between 60°C and 250°C, which may be above an acceptable inhalation temperature for a user. The heated volatile components cool as they travel through the cooling segment 107, 307, and some of the volatile components condense on the inner surface of the cooling segment 107, 307.

In the example of article 301 shown in Figures 3 and 4, cool air can enter cooling segment 307 through vents 317 formed in cooling segment 307. This cool air mixes with the heated volatile components to further cool the heated volatile components.

In another aspect, a method of forming an aerosol-forming material is provided, the aerosol-forming material comprising:
about 1% to about 30% by weight nicotine;
about 15 to about 80 weight percent of a gelling agent;
about 10 to about 60% by weight of an aerosol forming material;
about 1 to about 30 weight percent of an acid, and optionally a filler, where weight percent values are calculated on a dry weight basis;
The molar ratio of nicotine to acid is less than or equal to 2.2:1, and the method comprises:
(a) providing a slurry comprising nicotine, a gelling agent, an aerosol-forming material, an acid, a solvent, and any optional further components of the aerosol-generating material;
(b) forming a layer of the slurry;
(c) optionally solidifying or cross-linking the layer of slurry;
(d) drying the slurry to form an aerosol-generating material.

In another aspect, a method of forming an aerosol-forming material is provided, the aerosol-forming material comprising:
about 5% to about 30% by weight of a nicotine salt;
about 15 to about 80 weight percent of a gelling agent;
about 10 to about 60 weight percent of an aerosol-forming material, and optionally a filler, wherein weight percent values are calculated on a dry weight basis, the method comprising:
(a) providing a slurry comprising a nicotine salt, a gelling agent, an aerosol-forming material, an acid, a solvent, and any optional additional components of the aerosol-generating material;
(b) forming a layer of the slurry;
(c) optionally solidifying or cross-linking the layer of slurry;
(d) drying the slurry to form an aerosol-generating material.

In another aspect, a method of forming an aerosol-forming material is provided, the aerosol-forming material comprising:
about 1% to about 30% by weight of a nicotine salt;
about 45 to about 80% by weight of a gelling agent;
about 10 to about 54 weight percent of an aerosol-forming material; and optionally a filler, wherein weight percent values are calculated on a dry weight basis, the method comprising:
(a) providing a slurry comprising a nicotine salt, a gelling agent, an aerosol-forming material, an acid, a solvent, and any optional further components of the aerosol-generating material;
(b) forming a layer of the slurry;
(c) optionally solidifying or cross-linking the layer of slurry;
(d) drying the slurry to form an aerosol-generating material.

Another aspect of the invention provides a method of making a consumable or system as previously described. The method includes making an aerosol-generating material and incorporating the aerosol-generating material into the consumable or system. The method may include (a) forming a slurry including components of the aerosol-generating material or precursors thereof, (b) forming a layer of the slurry, (c) optionally solidifying or crosslinking the slurry, (d) drying to form the aerosol-generating material, and (e) incorporating the resulting aerosol-generating material into the consumable or system.

In step (a), nicotine or a nicotine salt may first be dissolved in an aerosol-forming material, and the resulting solution is then added to the other components of the slurry.

Step (b) of forming the layer of the slurry of the above method may include, for example, spraying, casting, or extruding the slurry. In some examples, the layer is formed by electrostatically spraying the slurry. In some examples, the layer is formed by casting the slurry.

In some examples, steps (b) and/or (c) and/or (d) may be performed at least partially simultaneously (e.g., during electrostatic spraying). In some examples, these steps may be performed sequentially.

In some instances, a solidifying or cross-linking agent (such as a calcium source) may be added to the slurry before or during step (b). This may be appropriate where gelling occurs relatively slowly (e.g., with an alginate gelling agent) and therefore the slurry may be, for example, cast after the solidifying agent has been added.

In another example, step (c) of solidifying or cross-linking the slurry may include adding a solidifying or cross-linking agent to the slurry layer. The solidifying or cross-linking agent may, for example, be sprayed onto the slurry or pre-loaded onto the surface onto which the slurry will be deposited.

For example, a solidifying or cross-linking agent containing a calcium source (such as calcium chloride or calcium citrate) may be added to a slurry containing alginate and/or pectin to form a calcium cross-linked alginate/pectin gel. In some instances where gelation occurs quickly (such as when a pectin gelling agent is used), calcium should be added after casting (because the slurry is too viscous to cast).

The total amount of solidifying or cross-linking agent, e.g., calcium source, may be 0.5-5% by weight (calculated on a dry weight basis). It has been found that adding too little solidifying or cross-linking agent may result in a gel that does not stabilize the optional flavoring, causing the flavoring to fall out of the gel. It has also been found that adding too much solidifying or cross-linking agent may result in a gel that is very sticky or very brittle, resulting in poor handling.

Alginates are derivatives of alginic acid and are typically high molecular weight polymers (10-600 kDa). Alginic acid is a copolymer of β-D-mannuronic acid (M) and α-L-guluronic acid (G) units (blocks) linked by (1,4)-glycosidic bonds to form a polysaccharide. When calcium cations are added, alginates crosslink to form a gel. Alginates with a high G monomer content may more readily form a gel upon addition of a calcium source. Thus, in some instances, the gel precursor may include an alginate in which at least about 40%, 45%, 50%, 55%, 60%, or 70% of the monomer units in the alginate copolymer are α-L-guluronic acid (G) units.

In some instances, the slurry may be warmed prior to and during casting. This may result in slow gelation, which improves handling and facilitates the casting process. Additionally, warming the slurry may melt optional flavor ingredients (e.g., menthol), facilitating handling.

In some instances, the menthol or other optional flavoring may be distributed throughout the slurry in powder form. In some instances, the menthol or other flavoring may be melted into the slurry (which may be warmed). In such instances, an emulsifier such as gum acacia may be added to disperse the molten menthol throughout the slurry.

In some instances, the slurry may be cast onto a band cast sheet. The sheet may be loaded with a releasing agent, such as lecithin, which may aid in the separation of the band cast from the aerosol-generating material.

In another aspect, a slurry is provided, the slurry comprising:
about 1% to about 30% by weight of nicotine;
about 15 to about 80 weight percent of a gelling agent;
about 10 to about 60 weight percent of an aerosol forming material;
about 1 to about 30 weight percent acid;
and optionally a filler (wherein weight percent values are calculated on a dry weight basis,
The molar ratio of nicotine to acid is less than or equal to 2.2:1.
and a solvent.

In another aspect, a slurry is provided, the slurry comprising:
about 5 to about 30% by weight of a nicotine salt;
about 15 to about 80 weight percent of a gelling agent;
about 10 to about 60 weight percent of an aerosol forming material;
optionally a filler, where weight percent values are calculated on a dry weight basis;
and a solvent.

In another aspect, a slurry is provided, the slurry comprising:
about 1% to about 30% by weight of a nicotine salt;
about 45 to about 80 weight percent of a gelling agent;
about 10 to about 54 weight percent of an aerosol forming material;
optionally a filler, where weight percent values are calculated on a dry weight basis;
and a solvent.

In some embodiments, the slurry solvent includes or is one or more of water, ethanol, methanol, dimethylsulfoxide, acetone, hexane, and toluene.

In certain embodiments, the slurry solvent may include water. In some instances, the slurry solvent may consist essentially of water or consist of water.

In some examples, the slurry may contain about 50%, 60%, 70%, 80%, or 90% solvent by weight (WWB).

In some examples, the slurry has a viscosity of about 1 to about 20 Pa·s at 46.5°C, e.g., about 10 to about 20 Pa·s at 46.5°C, e.g., about 14 to about 16 Pa·s at 46.5°C.

The discussion herein of aerosol-generating materials is expressly disclosed in combination with any slurry embodiment of the present invention.

Example embodiment 1.
about 1% to about 30% by weight of nicotine;
about 15 to about 80 weight percent of a gelling agent;
about 10 to about 60 weight percent of an aerosol forming material;
about 1 to about 30 weight percent acid;
and optionally a filler, wherein weight percent values are calculated on a dry weight basis;
An aerosol-forming material having a molar ratio of nicotine to acid of 2.2:1 or less.
1A.
about 1% to about 30% by weight of nicotine;
about 15 to about 80 weight percent of a gelling agent;
about 10 to about 60% by weight of an aerosol forming material;
about 1 to about 30 weight percent acid;
and optionally a filler (wherein weight percent values are calculated on a dry weight basis,
The molar ratio of nicotine to acid is less than or equal to 2.2:1.
A slurry comprising a solvent.
2. The aerosol-forming material of embodiment 1 or the slurry of embodiment 1A, comprising about 1-15% by weight nicotine.
3. The aerosol-forming material or slurry of embodiment 2, comprising about 1-10% by weight of nicotine.
4. The aerosol-forming material of embodiment 1 or the slurry of embodiment 1A, comprising about 3-15% by weight nicotine.
5. The aerosol-forming material or slurry of embodiment 4, comprising about 3-10% by weight of nicotine.
6. The aerosol-forming material of embodiment 1 or the slurry of embodiment 1A, comprising about 5-15% by weight nicotine.
7. The aerosol-forming material or slurry of embodiment 6, comprising about 5-10% by weight of nicotine.
8. The aerosol-forming material or slurry of any preceding embodiment comprising about 1-15% by weight acid.
9. The aerosol-forming material or slurry of embodiment 8, comprising about 1 to 10% by weight of an acid.
10. The aerosol-forming material or slurry of embodiment 8, comprising about 3 to 10% by weight of an acid.
11. The aerosol-forming material or slurry of embodiment 10, comprising about 3 to 10% by weight of an acid.
12. The aerosol-forming material or slurry of embodiment 10, comprising about 5 to 15% by weight of an acid.
13. The aerosol-forming material or slurry of embodiment 9, comprising about 5 to 10% by weight of an acid.
14. The aerosol-forming material or slurry of any preceding embodiment, wherein the molar ratio of nicotine to acid is 2:1 or less.
15. The aerosol-forming material or slurry of embodiment 14, wherein the molar ratio of nicotine to acid is 1.5:1 or less.
16. The aerosol-forming material or slurry of embodiment 15, wherein the molar ratio of nicotine to acid is 1 or less.
17. The aerosol-forming material or slurry of any preceding embodiment, wherein the molar ratio of nicotine to acid is 0.5:1 or greater.
18. The aerosol-forming material or slurry of embodiment 17, wherein the molar ratio of nicotine to acid is 0.7:1 or greater.
19. The aerosol-forming material or slurry of embodiment 18, wherein the molar ratio of nicotine to acid is 0.8:1 or greater.
20. The aerosol-forming material or slurry of any of embodiments 1-12, wherein the molar ratio of nicotine to acid is from 0.5:1 to 2.2:1.
21. The aerosol-forming material or slurry of embodiment 20, wherein the molar ratio of nicotine to acid is from 0.7:1 to 2:1.
22. The aerosol-forming material or slurry of embodiment 21, wherein the molar ratio of nicotine to acid is from 0.7:1 to 1.5:1.
23. The aerosol-forming material or slurry of any of the preceding embodiments, wherein the acid comprises at least one of succinic acid, lactic acid, benzoic acid, citric acid, tartaric acid, fumaric acid, levulinic acid, acetic acid, malic acid, formic acid, sorbic acid, benzoic acid, propanoic acid, and pyruvic acid.
23A. The aerosol-forming material or slurry of any of embodiments 1-22, wherein the acid comprises at least one of lactic acid, benzoic acid, levulinic acid, and pyruvic acid.
24. The aerosol-forming material or slurry of any of embodiments 1 to 22, wherein the acid comprises (or consists of) benzoic acid.
25. The aerosol-forming material or slurry of any of embodiments 1 to 22, wherein the acid comprises (or consists of) lactic acid.
26.
about 5 to about 30% by weight of a nicotine salt;
about 15 to about 80 weight percent of a gelling agent;
about 10 to about 60 weight percent of an aerosol forming material;
and optionally a filler, where weight percentages are calculated on a dry weight basis.
26A.
about 5 to about 30% by weight of a nicotine salt;
about 15 to about 80 weight percent of a gelling agent;
about 10 to about 60 weight percent of an aerosol forming material;
and optionally a filler, where weight percent values are calculated on a dry weight basis.
A slurry comprising a solvent.
27. The aerosol-forming material of embodiment 26 or the slurry of embodiment 26A, comprising about 5-15% by weight of a nicotine salt.
28. The aerosol-forming material or slurry of embodiment 27, comprising about 5-10% by weight of the nicotine salt.
29. The aerosol-forming material or slurry of any of embodiments 26-28, wherein the nicotine salt comprises nicotine benzoate.
30. The aerosol-forming material or slurry of any of embodiments 26-28, wherein the nicotine salt comprises nicotine lactate.
31. The aerosol-forming material or slurry of any preceding embodiment, comprising about 20-70% by weight of a gelling agent.
32. The aerosol-forming material or slurry of embodiment 31, comprising about 20-65% by weight of a gelling agent.
33. The aerosol-forming material or slurry of embodiment 31, comprising about 25-70% by weight of a gelling agent.
34. The aerosol-forming material or slurry of embodiment 33, comprising about 25 to 65% by weight of a gelling agent.
35. The aerosol-forming material or slurry of embodiment 33, comprising about 30-70% by weight of a gelling agent.
36. The aerosol-forming material or slurry of embodiment 35, comprising about 30 to 65% by weight of a gelling agent.
37. The aerosol-forming material or slurry of embodiment 35, comprising about 35 to 70% by weight of a gelling agent.
38. The aerosol-forming material or slurry of embodiment 37, comprising about 35 to 65% by weight of a gelling agent.
39. The aerosol-forming material or slurry of embodiment 37, comprising about 40-70% by weight of a gelling agent.
40. The aerosol-forming material or slurry of embodiment 39, comprising about 40 to 65% by weight of a gelling agent.
41. The aerosol-forming material or slurry of embodiment 39, comprising about 45 to 70% by weight of a gelling agent.
42. The aerosol-forming material or slurry of embodiment 41, comprising about 40 to 65% by weight of a gelling agent.
43. The aerosol-generating material or slurry of any preceding embodiment, comprising about 15-60% by weight of the aerosol-forming material.
43A. The aerosol-generating material or slurry of any preceding embodiment comprising about 15-55% by weight of the aerosol-forming material.
44. The aerosol-generating material or slurry of embodiment 43 or 43A, comprising about 15 to 50% by weight of the aerosol-forming material.
45. The aerosol-forming material or slurry of embodiment 43, comprising about 20-55% by weight of the aerosol-forming material.
46. The aerosol-forming material or slurry of embodiment 45, comprising about 20-50% by weight of the aerosol-forming material.
47. The aerosol-forming material or slurry of embodiment 45, comprising about 25-55% by weight of the aerosol-forming material.
48. The aerosol-forming material or slurry of embodiment 47, comprising about 25-50% by weight of the aerosol-forming material.
49. The aerosol-generating material or slurry of embodiment 47, comprising about 30-55% by weight of the aerosol-forming material.
50. The aerosol-forming material or slurry of embodiment 49, comprising about 30-50% by weight of the aerosol-forming material.
51.
about 1% to about 30% by weight of a nicotine salt;
about 45 to about 80 weight percent of a gelling agent;
about 10 to about 54 weight percent of an aerosol forming material;
and optionally a filler, where weight percentages are calculated on a dry weight basis.
51A.
about 1% to about 30% by weight of a nicotine salt;
about 45 to about 80 weight percent of a gelling agent;
about 10 to about 54 weight percent of an aerosol forming material;
optionally a filler, where weight percent values are calculated on a dry weight basis;
A slurry comprising a solvent.
52. The aerosol-forming material of embodiment 51 or the slurry of embodiment 51A, comprising about 1 to 15% by weight of a nicotine salt.
53. The aerosol-forming material or slurry of embodiment 52, comprising about 1-10% by weight of the nicotine salt.
54. The aerosol-forming material or slurry of embodiment 52, comprising about 3-15% by weight of the nicotine salt.
55. The aerosol-forming material or slurry of embodiment 54, comprising about 3-10% by weight of the nicotine salt.
56. The aerosol-forming material or slurry of embodiment 54, comprising about 5-15% by weight of the nicotine salt.
57. The aerosol-forming material or slurry of embodiment 56, comprising about 5-10% by weight of the nicotine salt.
58. The aerosol-forming material or slurry of any of embodiments 51-57, wherein the nicotine salt comprises nicotine benzoate.
59. The aerosol-forming material or slurry of any of embodiments 51-57, wherein the nicotine salt comprises nicotine lactate.
60. The aerosol-forming material or slurry of any of embodiments 51 to 59, comprising about 45 to 70% by weight of a gelling agent.
61. The aerosol-forming material or slurry of embodiment 60, comprising about 45 to 65% by weight of a gelling agent.
62. The aerosol-forming material or slurry of embodiment 60, comprising about 50-70% by weight of a gelling agent.
63. The aerosol-forming material or slurry of any one of embodiments 62, comprising about 50-65% by weight of a gelling agent.
64. The aerosol-generating material or slurry of any of embodiments 51-59, comprising about 15-60% by weight of the aerosol-forming material.
64A. The aerosol-forming material or slurry of any of embodiments 51-59, comprising about 15-50% by weight of the aerosol-forming material.
65. The aerosol-forming material or slurry of embodiment 64, comprising about 20-50% by weight of the aerosol-forming material.
66. The aerosol-forming material or slurry of embodiment 65, comprising about 25-50% by weight of the aerosol-forming material.
67. The aerosol-forming material or slurry of embodiment 66, comprising about 30-50% by weight of the aerosol-forming material.
68. The aerosol-forming material or slurry of any preceding embodiment, wherein the gelling agent comprises a hydrocolloid.
68. The aerosol generating agent or slurry of any preceding embodiment, wherein the gelling agent comprises (or is) one or more compounds selected from polysaccharide gelling agents, such as alginates, pectins, starches or derivatives thereof, cellulose or derivatives thereof, pullulan, carrageenan, agar and agarose, gelatin, gums, such as xanthan gum, guar gum and acacia gum, silica or silicone compounds, such as PDMS and sodium silicate, clays, such as kaolin, and polyvinyl alcohol.
69. The aerosol-forming material or slurry of any preceding embodiment, wherein the gelling agent comprises one or more polysaccharide gelling agents.
70. The aerosol-forming material or slurry of any preceding embodiment, wherein the gelling agent comprises one or more polysaccharide gelling agents.
71. The aerosol-forming material or slurry of any one of embodiments 68 to 70, wherein the polysaccharide gelling agent is selected from alginate, pectin, starch or derivatives thereof, cellulose or derivatives thereof.
72. The aerosol-forming material or slurry of embodiment 71, wherein the polysaccharide gelling agent is a cellulose derivative.
73. The aerosol-forming material or slurry of any of embodiments 69-72, wherein the cellulose or a derivative thereof is selected from hydroxymethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose (CMC), hydroxypropylmethylcellulose (HPMC), methylcellulose, ethylcellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), and cellulose acetate propionate (CAP).
74. The aerosol-forming material or slurry of embodiment 73, wherein the cellulose or derivative thereof is CMC.
75. The aerosol-forming material or slurry of embodiment 74, wherein CMC is the only gelling agent present in the aerosol-forming material or slurry.
76. The aerosol-forming material or slurry of embodiment 71, wherein the polysaccharide gelling agent is an alginate.
77. The aerosol-forming material or slurry of embodiment 76, wherein the alginate is the only gelling agent present in the aerosol-forming material or slurry.
78. The aerosol-forming material or slurry of embodiment 68, wherein the gelling agent comprises (or is) one or more of alginate, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol.
79. The aerosol-forming material or slurry of embodiment 68, wherein the gelling agent comprises (or is) one or more of hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, guar gum, acacia gum, alginate, and/or pectin.
80. The aerosol-forming material or slurry of any of embodiments 68-72, 73, 74, or 76-79, wherein the alginate is sodium alginate.
81. The aerosol-forming material or slurry of any preceding embodiment, wherein the gelling agent is not crosslinked.
82. The aerosol generating material or slurry of any preceding embodiment, wherein the aerosol generating agent comprises (or is) one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.
83. The aerosol-generating material or slurry of embodiment 82, wherein the aerosol generating agent comprises (or is) one or more of erythritol, propylene glycol, glycerol, and triacetin.
84. The aerosol-generating material or slurry of embodiment 82 or 83, wherein the aerosol generating agent comprises (or is) glycerol, optionally in combination with propylene glycol.
85. The aerosol-forming material or slurry of any preceding embodiment, comprising less than about 10% by weight of a filler.
86. The aerosol-forming material or slurry of embodiment 85, comprising less than about 5% by weight of a filler.
87. The aerosol-forming material or slurry of embodiment 86, comprising less than about 1% by weight of a filler.
88. The aerosol-forming material or slurry of any of the preceding embodiments, comprising 1 to 10% by weight of a filler.
89. The aerosol-forming material or slurry of embodiment 88, comprising 1 to 5% by weight of a filler.
90. The aerosol-forming material or slurry of embodiment 88, comprising 2 to 7% by weight of a filler.
91. The aerosol-forming material or slurry of any of the preceding embodiments, comprising 3 to 10% by weight of a filler.
92. The aerosol-forming material or slurry of embodiment 91, comprising 3 to 5% by weight of a filler.
93. The aerosol-forming material or slurry of any of embodiments 85-92, wherein the filler is selected from inorganic filler materials, wood pulp, hemp fibers, cellulose, and cellulose derivatives.
94. The aerosol-forming material or slurry of embodiment 93, which does not contain calcium carbonate, such as chalk.
95. The aerosol-forming material or slurry of any of the preceding embodiments, which does not include a filler.
96. The aerosol-forming material or slurry of any preceding embodiment, comprising an additional active agent.
97. The aerosol-forming material or slurry of any preceding embodiment, further comprising one or more other functional materials.
98. The aerosol-forming material or slurry of any preceding embodiment, which does not include fibrous material.
99. The aerosol-forming material or slurry of any of the preceding embodiments, which does not include tobacco fibers.
99A. The aerosol-forming material or slurry of any of the preceding embodiments, comprising less than 1% by weight of tobacco.
99B. The aerosol-forming material or slurry of any of embodiments 1-98, comprising less than 0.5% by weight of tobacco.
99C. The aerosol-forming material or slurry of any of embodiments 1-98, which does not contain tobacco.
100. The aerosol-forming material or slurry of any preceding embodiment, further comprising water.
101. An aerosol-forming composition comprising an aerosol-forming material according to any preceding embodiment.
102. The aerosol forming composition of embodiment 101, further comprising one or more additional active agents and/or fragrances, and optionally one or more other functional materials.
103. The aerosol forming composition of embodiment 101 or 102, further comprising one or more other functional materials.
104. The aerosol forming composition of embodiment 102 or 103, wherein the other functional materials comprise one or more pH adjusters, colorants, preservatives, binders, stabilizers, and/or antioxidants.
105. The aerosol-forming composition of any of embodiments 101-104, comprising about 50-100% by weight (by WWB) of the aerosol-forming material.
106. The aerosol forming composition of embodiment 105, comprising about 50 to 90% by weight (by WWB) of the aerosol forming material.
107. The aerosol forming composition of embodiment 105, comprising about 60 to 100% by weight (by WWB) of the aerosol forming material.
108. The aerosol forming composition of embodiment 107, comprising about 60 to 95% by weight (by WWB) of the aerosol forming material.
109. The aerosol forming composition of embodiment 107, comprising about 70 to 100% by weight (by WWB) of the aerosol forming material.
110. The aerosol forming composition of embodiment 109, comprising about 70-95% by weight (by WWB) of the aerosol forming material.
111. The aerosol forming composition of embodiment 110, comprising about 70-90% by weight (by WWB) of the aerosol forming material.
112. The aerosol-forming composition of any of embodiments 101-104, consisting or consisting essentially of an aerosol-forming material.
112A. The aerosol forming composition of any of embodiments 101-112, comprising a carrier in which the aerosol forming material is disposed.
112B. The aerosol forming composition of embodiment 112A, wherein the carrier comprises a metal foil.
112C. The aerosol forming composition of embodiment 112B, wherein the carrier comprises aluminum foil.
113. A consumable for use in a non-combustion aerosol delivery device, comprising the aerosol forming composition of any of embodiments 101-112.
113A. The consumable of embodiment 113, wherein the consumable does not contain tobacco.
113B. The consumable product of any of embodiments 113-113A, wherein the aerosol forming composition consists of the aerosol forming material of any of embodiments 1-100.
113C. The consumable of any one of embodiments 113-113B, comprising a single aerosol generating composition.
114. A non-combustion aerosol delivery system comprising the consumable of embodiment 113 and a non-combustion aerosol delivery device.
115. The consumable used in the non-combustion aerosol delivery device of embodiment 113 or the non-combustion aerosol delivery system of embodiment 114, wherein the non-combustion aerosol delivery device is a non-combustion heated device.
116. The consumable for use in the non-combustion aerosol delivery device of embodiment 113 or the non-combustion aerosol delivery system of embodiment 114, wherein the non-combustion aerosol delivery device is an e-cigarette hybrid device.
117. A method of forming an aerosol-forming material as defined in any of embodiments 1-25, 31-50, and 68-100, comprising:
(a) providing a slurry comprising a gelling agent, an aerosol-forming material, nicotine, an acid, a solvent and any optional further components of the aerosol-generating material;
(b) forming a layer of the slurry;
(c) optionally allowing the layer of slurry to solidify;
(d) drying the slurry to form an aerosol-generating material.
118. A method of forming an aerosol-forming material as defined in any of embodiments 26-100, comprising:
(a) providing a slurry comprising a gelling agent, an aerosol-forming material, a nicotine salt, a solvent and any optional further components of the aerosol-generating material;
(b) forming a layer of the slurry;
(c) optionally allowing the layer of slurry to solidify;
(d) drying the slurry to form an aerosol-generating material.
119. The method of embodiment 117 or 118, wherein the solvent comprises water.
120. The method of embodiment 117 or 118, wherein the solvent consists essentially of, or consists of, water.
121. The method of any of embodiments 117-120 or the slurry of any of embodiments 1-100, wherein the slurry comprises about 50%, 60%, 70%, 80%, or 90% by weight of solvent (by WWB).

Exemplary non-limiting formulations of aerosol-generating materials (AM) are shown in the table below.

Claims (42)

1. An aerosol forming composition comprising an aerosol forming material, the aerosol forming material comprising:
about 1% to about 30% by weight of nicotine;
about 15 to about 80 weight percent of a gelling agent;
about 10 to about 60 weight percent of an aerosol forming material;
about 1 to about 30 weight percent acid;
and optionally a filler, wherein weight percent values are calculated on a dry weight basis;
An aerosol forming composition having a molar ratio of nicotine to acid of 2.2:1 or less. The aerosol generating composition of claim 1, wherein the molar ratio of nicotine to acid is 1.5:1 or less. The aerosol generating composition of claim 1, wherein the molar ratio of nicotine to acid is 1:1 or less. The aerosol generating composition of any one of claims 1 to 3, wherein the molar ratio of nicotine to acid is 0.5:1 or greater. The aerosol generating composition of any one of claims 1 to 4, wherein the acid comprises one or more of lactic acid, benzoic acid, levulinic acid, and pyruvic acid. The aerosol generating composition of any one of claims 1 to 5, wherein the acid comprises benzoic acid. The aerosol generating composition of any one of claims 1 to 6, wherein the nicotine is present in an amount of about 6 to about 30% by weight. 1. An aerosol forming composition comprising an aerosol forming material, the aerosol forming material comprising:
about 5 to about 30% by weight of a nicotine salt;
about 15 to about 80 weight percent of a gelling agent;
about 10 to about 60 weight percent of an aerosol forming material;
and optionally a bulking agent, where weight percent values are calculated on a dry weight basis. 1. An aerosol forming composition comprising an aerosol forming material, the aerosol forming material comprising:
about 1% to about 30% by weight of a nicotine salt;
about 45 to about 80 weight percent of a gelling agent;
about 10 to about 54 weight percent of an aerosol forming material;
and optionally a bulking agent, where weight percent values are calculated on a dry weight basis. The aerosol generating composition of any one of claims 1 to 9, wherein the aerosol generating material comprises less than 10% by weight of a filler. The aerosol generating composition of any one of claims 1 to 10, wherein the aerosol generating material comprises about 5% by weight of a filler. The aerosol-forming composition of any one of claims 1 to 11, wherein the aerosol-forming material comprises wood pulp. The aerosol generating composition of any one of claims 1 to 11, wherein the aerosol generating material does not contain a filler. The aerosol generating composition of any one of claims 1 to 13, wherein the gelling agent comprises one or more compounds selected from the group including alginates, cellulose derivatives, gums, silica or silicon compounds, clays, and combinations thereof. The aerosol generating composition of any one of claims 1 to 14, wherein the gelling agent comprises alginate and/or carboxymethylcellulose. The aerosol-forming composition according to any one of claims 1 to 15, wherein the aerosol-forming material further comprises a cross-linking agent. The aerosol generating composition of claim 16, wherein the cross-linking agent comprises calcium ions. The aerosol-forming composition of any one of claims 1 to 15, wherein the aerosol-forming material does not contain a crosslinking agent. The aerosol generating composition of any one of claims 1 to 18, wherein the gelling agent is present in an amount of about 45 to about 70% by weight. The aerosol generating composition of any one of claims 1 to 19, wherein the aerosol forming material comprises one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, phenylbenzyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. The aerosol generating composition according to any one of claims 1 to 20, wherein the aerosol forming material comprises glycerol. The aerosol generating composition of any one of claims 1 to 21, wherein the aerosol forming agent is present in an amount of about 15 to about 50% by weight. The aerosol-forming composition of any one of claims 1 to 22, wherein the aerosol-forming material is substantially free of tobacco. The aerosol-generating composition according to any one of claims 1 to 23, wherein the aerosol-generating material is in the form of a film. The aerosol-generating composition of any one of claims 1 to 23, wherein the aerosol-generating material is in the form of a strip, a corrugated sheet, a gathered sheet, or a shredded sheet. The aerosol-generating composition according to any one of claims 1 to 25, wherein the aerosol-generating material comprises a fragrance. The aerosol-generating composition of claim 26, wherein the aerosol-generating material comprises about 1 to about 65% by weight of a flavoring agent. The aerosol-generating composition according to any one of claims 1 to 27, comprising the aerosol-generating material. A consumable for use with a non-combustion aerosol delivery system, comprising the aerosol generating composition of any one of claims 1 to 28. The consumable product of claim 29, which does not contain tobacco. The consumable product of claim 29 or 30, wherein the aerosol-generating composition comprises nicotine, a gelling agent, an aerosol-forming material, an acid, and optionally a flavoring agent and/or an optional filler. The consumable product according to any one of claims 29 to 31, comprising a single aerosol generating composition, the aerosol generating composition being as described in any one of claims 1 to 28. The consumable product according to any one of claims 29 to 32, wherein the aerosol-generating composition is in the form of a film. A non-combustion aerosol delivery system comprising a consumable according to any one of claims 29 to 33 and a non-combustion aerosol delivery device, the non-combustion aerosol delivery device comprising an aerosol generating device arranged to generate an aerosol from the consumable when the consumable is used with the non-combustion aerosol delivery device. Use of the aerosol generating composition of any one of claims 1 to 28 in a consumable for use with a non-combustion aerosol delivery device, the non-combustion aerosol delivery device comprising an aerosol generating device arranged to generate an aerosol from the consumable when the consumable is used with the non-combustion aerosol delivery device. about 1% to about 30% by weight of nicotine;
about 15 to about 80 weight percent of a gelling agent;
about 10 to about 60 weight percent of an aerosol forming material;
about 1 to about 30 weight percent acid;
Optionally, a filler and a solvent, where weight percent values are calculated on a dry weight basis;
The slurry has a nicotine to acid molar ratio of 2.2:1 or less. about 5 to about 30% by weight of a nicotine salt;
about 15 to about 80 weight percent of a gelling agent;
about 10 to about 60 weight percent of an aerosol forming material;
A slurry, optionally including a filler and a solvent, with weight percentages calculated on a dry weight basis. about 1% to about 30% by weight of a nicotine salt;
about 45 to about 80 weight percent of a gelling agent;
about 10 to about 54 weight percent of an aerosol forming material;
A slurry, optionally including a filler and a solvent, with weight percentages calculated on a dry weight basis. The slurry of claim 36, 37 or 38, wherein the solvent is water. 29. A method of making an aerosol-forming composition according to any one of claims 1 to 28, wherein the aerosol-forming composition comprises an aerosol-forming material, the method comprising:
(i)
about 1% to about 30% by weight nicotine;
about 15 to about 80 weight percent of a gelling agent;
about 10 to about 60% by weight of an aerosol forming material;
about 1 to about 20 weight percent of an acid, and optionally a filler, wherein these weights are calculated on a dry weight basis;
the molar ratio of nicotine to acid is less than 2.2:1; and
or about 5 to about 30% by weight of a nicotine salt;
about 15 to about 80 weight percent of a gelling agent;
combining about 10 to about 60% by weight of an aerosol-forming material, and optionally a bulking agent, wherein these weights are calculated on a dry weight basis, and a solvent;
or about 1% to about 30% by weight of a nicotine salt;
about 45 to about 80% by weight of a gelling agent;
combining about 10 to about 54 weight percent of an aerosol-forming material, and optionally a bulking agent, wherein weight percent values are calculated on a dry weight basis, and a solvent;
(ii) forming a layer of the slurry;
(iii) drying to form the aerosol-generating material; and
A method comprising: An aerosol-generating composition formed by the method of claim 40. A method of generating an aerosol containing a nicotine salt using the non-combustion aerosol delivery system of claim 34, comprising the step of heating the aerosol generating composition, optionally to a temperature of less than 350°C.

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